Packaging product with thermal and mechanical insulation features

ABSTRACT

A packaging product taking the form of a thermally insulating packaging material includes a first multi-layer film bonded to a second layer of multi-layer film. Each multi-layer film can include one or more polymer layers and one or more metallized layers. The multi-layer films are bonded to each other with a pattern that leaves a number of inflatable cells dispersed across a surface of the sheet. At least one end of the sheet can be left unbonded. The uninflated packaging product can be stored and distributed in its uninflated state prior to it being used as a packaging material. Once ready for use, the cells can be inflated through the unbonded ends and the unbonded ends of the sheets can then be sealed to form a robust sheet of thermally insulating packaging material.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.15/690,080 filed on Aug. 29, 2017; which is a continuation of U.S.application Ser. No. 14/810,274 filed on Jul. 27, 2015, now U.S. Pat.No. 9,757,925; which claims priority under 35 U.S.C. § 119(e) to U.S.Provisional Application No. 62/029,317 filed on Jul. 25, 2014. Thecontents each of these applications are hereby incorporated by referencefor all purposes.

FIELD

The described embodiments relate generally to the production ofinflatable packaging materials. More particularly, the presentembodiments relate to packaging materials that can be distributed tousers of the packaging materials in an uninflated state.

BACKGROUND OF THE INVENTION

Packaging materials taking the form of laminated or heat sealed filmlayers defining numerous discrete pockets of air have been commonly usedin the industry to reduce the stress of impacts upon items beingtransported. While these types of packaging materials can reduce thetransmission of stresses or impacts received by a shipping container toan item carried within the shipping container, the spacing between thediscrete pockets of air can prevent the packaging materials fromproviding a robust thermal barrier suitable for maintaining atemperature of the item being carried within the shipping container. Forat least this reason, improvements in shipping materials that alsoprovide excellent thermal insulation are highly desirable.

BRIEF SUMMARY OF THE INVENTION

This paper describes various embodiments that relate to thermallyinsulating shipping materials.

The present invention relates generally to packaging technology. Moreparticularly, embodiments of the present invention relate to methods andsystems for packaging materials that provide improved thermal insulationin comparison with conventional solutions. Applications of the presentinvention include use in pouches, pallet covers, alternatives toconventional bubble wrap materials, thermal bags, and the like. Theinvention has wider applicability than this example and is suitable forapplication to other packaging applications.

According to an embodiment of the present invention, an insulatingpackaging material is provided. The insulated packaging material, whichcan be referred to as a laminated or heat sealed structure and canprovide a flexible insulating material to be converted in packagingmaterials, includes a first multi-layer film including a first polymerlayer and a first metallized layer. The insulated packaging materialalso includes a second multi-layer film including a second polymer layerand a second metallized layer. The first multi-layer film is joined tothe second multi-layer film over a bonded region. The bonded region isinterspersed with unbonded regions that when filled with gas form anarray of adjacent hexagonal shapes.

Numerous benefits are achieved by way of the present invention overconventional techniques. For example, embodiments of the presentinvention provide packaging materials that are useful for shipping ortransporting of perishable or temperature sensitive products. Thedescribed embodiments include embedding metallized layers withininflatable packaging materials using one or more polymer layers, therebyincreasing thermal insulation performance.

Other aspects and advantages of the invention will become apparent fromthe following detailed description taken in conjunction with theaccompanying drawings which illustrate, by way of example, theprinciples of the described embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure will be readily understood by the following detaileddescription in conjunction with the accompanying drawings, wherein likereference numerals designate like structural elements, and in which:

FIG. 1A shows a plan view of packaging material having a pattern ofhexagonally shaped cells, according to an embodiment of the presentinvention;

FIG. 1B shows an annotated plan view of the flexible packaging materialillustrated in FIG. 1A;

FIG. 1C shows a plan view of the inflated flexible packaging materialwith the pattern of hexagonally shaped cells sealed to trap gases withinthe cells;

FIG. 2A shows a plan view of a sheet of flexible packaging materialhaving a square or rectangular pattern of cells, according to anembodiment of the present invention;

FIG. 2B shows an annotated plan view of the flexible packaging materialillustrated in FIG. 2A;

FIG. 2C shows a plan view of the inflated flexible packaging materialdepicted in FIG. 2A heat sealed at opposing ends to trap gases withinthe cells;

FIG. 3 shows a more detailed plan view of the flexible packagingmaterial illustrated in FIG. 1A;

FIG. 4A shows a cross-sectional view of the flexible packaging materialillustrated in FIG. 3 during an inflation operation;

FIGS. 4B-4D show cross-sectional views of the flexible packagingmaterial illustrated in FIG. 3 after inflation in accordance withsection line A-A; and

FIG. 4E shows a cross-sectional view of the flexible packaging materialillustrated in FIG. 3 after inflation in accordance with section lineB-B.

DETAILED DESCRIPTION OF THE INVENTION

Representative applications of methods and apparatus according to thepresent application are described in this section. These examples arebeing provided solely to add context and aid in the understanding of thedescribed embodiments. It will thus be apparent to one skilled in theart that the described embodiments may be practiced without some or allof these specific details. In other instances, well known process stepshave not been described in detail in order to avoid unnecessarilyobscuring the described embodiments. Other applications are possible,such that the following examples should not be taken as limiting.

In the following detailed description, references are made to theaccompanying drawings, which form a part of the description and in whichare shown, by way of illustration, specific embodiments in accordancewith the described embodiments. Although these embodiments are describedin sufficient detail to enable one skilled in the art to practice thedescribed embodiments, it is understood that these examples are notlimiting; such that other embodiments may be used, and changes may bemade without departing from the spirit and scope of the describedembodiments.

Embodiments of the present invention provide a flexible packagingmaterial that includes a lamination of two or more layers of film with aheat seal or adhesive pattern. These packaging materials are useful fora variety of thermal insulation applications. As described herein, twoor more multilayer films are heat sealed using a continuous orsemi-continuous pattern. The multilayer films include one or more layersthat are a metallized film along the lines of a metallized polyesterfilm or in some embodiments a thin sheet of aluminum foil. Themultilayer films also include one or more polymer layers that canenclose an oxygen barrier layer that allows the finished product to beinflated for an extended period of time and provides for increasedamounts of thermal insulation. The lamination process (either hot orcold lamination) joins the multi-layer films together. In someembodiments, the polymer layers can be disposed on the outside of thefinished product, while in other embodiments the metallized film oraluminum foil layers can be positioned along an exterior of thematerial. Various embodiments of the present invention are describedthat enable the formation of close cell-to-cell spacing, which providerobust thermal insulation properties for the joined multilayer filmsafter inflation. While substantially planar sheets of packaging materialare depicted throughout this paper, it should be understood that thedescribed packaging materials can be shaped and manipulated in manyways. In some embodiments, the packaging materials can take the form ofpouches, bags and panels of varying shape and size.

These and other embodiments are discussed below with reference to FIGS.1A-4E; however, those skilled in the art will readily appreciate thatthe detailed description given herein with respect to these figures isfor explanatory purposes only and should not be construed as limiting.

FIG. 1A shows a plan view of a section of a flexible packaging materialstructure having a hexagonal pattern of cells 102. The pattern of cells102 includes a continuous pattern along vertical directions from oneedge of the pattern to another edge. The pattern includes breaks alongthe vertical directions to enable gas (e.g. compressed air, argon, CO₂or a mixture of noble gases with krypton/xenon) to pass from onehexagonally shaped cell to another (the cells along a vertical can bereferred to as a chain of cells) during inflation. The hexagonal cellshape in cooperation with the hexagonal cell arrangement allow forparticularly close spacing of the cells, thereby maximizing an area ofthe flexible packaging material defining and enclosing a robust layer ofair. It should be noted that while the hexagonal cells are shown asbeing precisely hexagonal it should be understood that generallyspeaking a footprint or portion of the packaging material that is notbonded together can be hexagonal and a resulting shape of the cell wheninflated will be substantially hexagonal in shape. It should also benoted that the while a vertical pattern of connected hexagonally shapedcells is depicted, the breaks defining the chains of cells couldalternatively be oriented in diagonal or horizontal directions. In someembodiments, two or more adjacent chains of cells can be linked tosimplify inflation operations.

FIG. 1B is an annotated plan view of the flexible packaging materialstructure illustrated in FIG. 1A. As illustrated in FIG. 1B, eachvertical chain of cells is independent from the other vertical chains tomaintain performance of adjacent chains if one cell in the chain ofcells is punctured. The arrows in FIG. 1B indicate inflation points 104through which a gas can be introduced in order to inflate the structurewith gas disposed between opposing portions of the films. The flexiblepackaging material structure can be inflated in many ways, including forexample, by a single valve or alternatively by a continuous inflationprocess. Peripheral edges of the packaging material can be sealed duringinflation while moving along the peripheral edge of the packagingmaterial. The described methods can be utilized in conjunction with theinflation points. In some embodiments, heat seals can be arranged alonga perimeter or lateral portion of the packaging material to define thesurface of the pouch, bag or cover. Along each vertical chain ofhexagonal cells, breaks are positioned at opposing sides of the hexagonsand take the form of orifices 106 that provide for gas flow along arespective vertical chain. The set of opposing orifices constitutes abreak in the sealing pattern, preventing the two films from being joinedat the position of the orifices. Thus, along the vertical, the hexagonalshapes are effectively unsealed and in fluid communication each otherand the ambient atmosphere.

Embodiments of the present invention are fabricated by laminating thetwo coextruded or laminated multi-layer films, with the films joined atthe bonding region. The interior regions of the hexagonal structures arein fluid communication with atmosphere through the orifices runningalong each chain of hexagonal cells. Not only do the orifices providefor flow of gas along the chains, but the inflation points 104 locatedat the end of each chain of hexagonal cells provides for inflation ordeflation of each the chain. Accordingly, in contrast with conventionalbubble wrap, which is manufactured and distributed in an inflated state,embodiments of the present invention can be manufactured (e.g.,laminated) and then shipped in an uninflated condition to an end user.

End users of the shipping materials can then inflate the shippingmaterials and seal the inflated structure prior to use, for example, bysealing the periphery of the array of hexagonal cells as illustrated inFIG. 1C. Thus, embodiments of the present invention reduce deliverycosts since the shipping materials can be delivered from themanufacturer to the end user in the uninflated state, thereafterinflated by the end user, and utilized to ship products from the enduser to their customers. In this way, shipments of the shippingmaterials can enjoy substantial volumetric savings when compared withinflated shipping materials.

FIG. 2A is a plan view of a sheet of flexible packaging material formedfrom two multi-layer films that cooperate to form a pattern of squarecells according to an embodiment of the present invention. Althoughsquare cells are illustrated, other rectangular cells are includedwithin the scope of the present invention. FIG. 2B is an annotated planview of the square seal pattern illustrated in FIG. 2A. Each column isindependent of the other columns and the columns include orifices in therectangular shapes, allowing fill gas (e.g., air, nitrogen, or the like)to enter through the orifice at the top or bottom of each column andthen flow into the cells along the column, filling the column andseparating the thin films not joined at the bonding region. The arrowsdepicted in FIG. 2B show a location of openings suitable for receivingair to inflate the cells of the sheet of flexible packaging material.After filling, the columns can be sealed at the top and bottom by heatseals 202 and 204, which heat seal the top and bottom cells in eachcolumn, i.e., at the periphery, as shown in FIG. 2C. Accordingly,puncturing of a cell in row 3 will not result in damage to rows 2 and 4.

FIG. 3 is a plan view of inflatable packaging product 300 withhexagonally shaped cells according to an embodiment of the presentinvention. Embodiments of the present invention reduce or minimize thegap between the inflated cells after inflation. As illustrated in FIG.3, hexagonal cells 102 are connected by gas passages or orifices 106passing through opposing sides of the hexagons from top to bottom, whichis also the layout illustrated in FIG. 1A. After filling, the majorityof the surface area includes spatial separation between the two filmlayers, providing high thermal performance. In some embodiments, thedistance between cells is less than ⅛″, for example on the order of1/16″ or 1/32″. The use of hexagons as illustrated in FIGS. 1A-1B orrectangular shapes as illustrated in FIG. 2A-2B, reduces the spatialdimension of the bonding region when compared with more conventionalcircularly shaped cell configuration. Since the packing density ishigher than the circular shaped configurations, the thermal performancecan be particularly strong in comparison.

FIG. 4A shows a cross-sectional view of inflatable packaging product 300in accordance with cross-section A-A as it undergoes inflation formedfrom multi-layer films 402 and 404. In particular, various dimensions ofthe packaging product are shown in FIG. 4A. In some embodiments, a width406 of hexagonal cell 102 can be on the order of about 0.3-0.7 inches.An overall thickness 408 of the inflated packaging product can be on theorder of between 0.35-0.75 inches and an average distance 410 betweenadjacent cells 102 can be between 0.03-0.1 inches. An overall uninflatedthickness of the inflatable packaging product can be equivalent to athickness of the layers of film that join it together, particularly whenthe cells are evacuated of any gases when distributed. FIG. 4A alsoshows how adjacent cells 102 can be filled sequentially as gases fillthe packaging product.

FIG. 4B shows another cross-sectional view of inflatable packagingproduct 300. Detailed views 412 and 414 show a micro-structure ofmulti-layer film 402 and 404 that are joined to form inflatablepackaging product 300. Multi-layer film 402 can be a co-extrudedmulti-layer film including a polymer layer 416 that defines oxygenbarrier 418, taking the form of a thin layer of air trapped withinpolymer layer 416. When polymer layer 416 is a co-extruded layer formedof multiple polymer layers a binding polymer layer is included as well.Polymer layer 416 can alternatively be formed from a single polymer.Polymer layer 416, provides mechanical support for the metallizationlayer in addition to defining oxygen barrier 418. In someimplementations, polymer layer 416 can include one or more of thefollowing materials or combinations thereof, polypropylene (PP),polyethylene terephthalate (PET), high-density polyethylene (HDPE),low-density polyethylene (LDPE), nylon, ethylene vinyl alcohol (EVOH) orany suitable polymer with heat sealing capability. Although a singlepolymer layer 416 is illustrated in detailed view 412, polymer layer 416can include additional sub-layers, providing a multi-layer stacksuitable as a substrate for deposition or lamination of metallizationlayer 420. In some embodiments, multi-layer films 402 and 404 caninclude multiple polymer layers and can be interspersed with multiplemetallization layers 420. It should be noted that the choice ofmaterials used to form polymer layer 416 can change the position ofoxygen barrier with respect to other layers of multi-layer films 402 and404. For example, in embodiments where polymer layer 416 is formed fromHDPE, PP, Surlyn® or from other polymers having relatively lower meltingpoints, oxygen barrier 418 can be positioned between polymer layer 416and metallization layer 420. Additionally, metallization layer 420 isillustrated in detailed view 412 as a single layer, but this is notrequired by the present invention. Multiple layers of metallization withdifferent material properties can be utilized according to an embodimentof the present invention. In a particular embodiment, metallizationlayer 420 can take the form of a single layer of aluminum. One ofordinary skill in the art would recognize many variations,modifications, and alternatives.

Detailed view 414 shows another portion of inflatable packaging product300, in particular a portion of multi-layer film 404. Themicro-structure of a multi-layer film 404 can be substantially the sameas multi-layer film 402 as depicted or it can also be different.Accordingly, multi-layer film 404 is depicted as a metalized layer 420and a polymer layer 416 defining and entrapping gases within an oxygenbarrier layer 418. While the term oxygen in oxygen barrier layer is usedby way of example it should be understood that any gas could beentrapped within oxygen barrier layer 418. Furthermore, in someembodiments, various subtle differences could be included in a thicknessand or density of polymer layers 416. FIGS. 4C and 4D show specificexamples of ways in which the multi-layer films can be configured.

FIG. 4C shows how metallization layer 420 can be attached only tomulti-layer film 402, while multi-layer film 404 does not includemetallization layer 420. Furthermore, FIG. 4C shows an inner portion ofpolymer layer indicated as layer 422. In some embodiments, layer 422 canbe substantially different than layer 416. For example, in someembodiments a substantially thicker layer 416 can be desirable to reducea risk of tearing to an exterior layer of inflatable packaging product300. FIG. 4D shows how metallization layer 420 can be disposed on anexterior surface of inflatable packaging product 300. While notdepicted, in some embodiments metallization layer can be positioned onan exterior surface of multi-layer film 402 and an interior surface ofmulti-layer film 404.

FIG. 4E depicts a cross-sectional view of inflatable packaging product300 in accordance with section line B-B. As depicted, multi-layer films402 and 404 are positioned so that metallization layers 420 are joinedtogether at a bonded region taking the form of interface 422 to form thepackaging product, which can serve as an insulating structure. In someembodiments, multi-layer films 402 and 404 are joined by lamination,heat sealing or hot melt processes. The converted product, afterformation, can remain in the unfilled, uninflated, state during shipmentto the end user, which will inflate the packaging product prior to enduse. In this manner, the size of the packaging product is smaller duringmanufacturing and/or shipment to end users than for conventionalproducts that are inflated during manufacture, for example, conventionalbubble wrap.

Some embodiments of the present invention contrast with packaging, whichcan include a bubble wrap layer laminated with a sheet of metalized filmor laminated aluminum foil. In these packaging materials, the metalmaterial is located on the exterior of the packaging materials (facingoutward), which increases thermal conductivity from the environment tothe metal materials and degrades thermal performance. In the embodimentsdescribed herein, during manufacturing, the metalized film layers arepositioned facing each other and joined together at the bonding regionsuch that the metalized film layers are disposed on the internal portionof the finished structure and utilized in the heat sealing process asthe metalized film layers are joined together. It should be noted thatadding the metalizing layer on the exterior surface of the packaging canstill be effective as it still provides an alternating structure ofpolymer and metallization that would tend to impede the transfer of heatthrough the packaging material.

In embodiments in which radiation operates to transfer heat, the lowemissivity of polymer layers in comparison with metal layers, results inbetter thermal performance for shipping materials in which themetallized layers are disposed between polymer layers as illustratedherein. The enclosure of metallized layers within the polymer layerscontrasts with conventional structures in which the metallization isapplied as an exterior layer, characterized by a high emissivity, highradiation loss, and poor thermal performance. In addition to radiation,heat transfer through conduction and convection are also limited byenclosing the metallized layers within the polymer layers. One ofordinary skill in the art would recognize many variations,modifications, and alternatives.

The various aspects, embodiments, implementations or features of thedescribed embodiments can be used separately or in any combination.Various manufacturing aspects of the described embodiments can beimplemented by software, hardware or a combination of hardware andsoftware. The foregoing description, for purposes of explanation, usedspecific nomenclature to provide a thorough understanding of thedescribed embodiments. However, it will be apparent to one skilled inthe art that the specific details are not required in order to practicethe described embodiments. Thus, the foregoing descriptions of specificembodiments are presented for purposes of illustration and description.They are not intended to be exhaustive or to limit the describedembodiments to the precise forms disclosed. It will be apparent to oneof ordinary skill in the art that many modifications and variations arepossible in view of the above teachings.

1. (canceled)
 2. An insulating packaging material, comprising: a firstinsulating structure comprising: a first multi-layer film including afirst polymer layer; and a second multi-layer film including a secondpolymer layer and a first metallized layer, wherein the firstmulti-layer film is joined to the second multi-layer film over a firstbonded region, the first bonded region being interspersed with unbondedregions that when filled with gas form a first array of adjacent cells;and a second insulating structure comprising: a third multi-layer filmincluding a third polymer layer; and a fourth multi-layer film includinga fourth polymer layer and a second metallized layer, wherein the thirdmulti-layer film is joined to the fourth multi-layer film over a secondbonded region, the second bonded region being interspersed with unbondedregions that when filled with gas form a second array of adjacent cells.3. The insulating packaging material of claim 2 wherein the firstpolymer layer and the second polymer layer define a first oxygen barrierlayer trapped within the first polymer layer and the second polymerlayer, and wherein the third polymer layer and the fourth polymer layerdefine a second oxygen barrier layer trapped within the third polymerlayer and the fourth polymer layer.
 4. The insulating packaging materialof claim 2 wherein each adjacent cell of the first array of adjacentcells and the second array of adjacent cells include a set of orifices,each orifice of the set of orifices being positioned on a different sideof each adjacent cell.
 5. The insulating packaging material of claim 4wherein each adjacent cell of the first array of adjacent cells havehexagonal geometries, and wherein the first array of adjacent cells isarranged in a plurality of substantially linear rows, the set oforifices allowing each of the plurality of substantially linear rows ofthe first array of adjacent cells to be inflated concurrently.
 6. Theinsulating packaging material of claim 2 wherein a ratio of a width ofeach cell of the first array of adjacent cells to an average distancebetween each cell of the first array of adjacent cells is at least 3 to1.
 7. The insulating packaging material of claim 2 wherein a ratio of awidth of each cell of the second array of adjacent cells to an averagedistance between each cell of the second array of adjacent cells is atleast 3 to
 1. 8. The insulating packaging material of claim 7 whereinthe first metallized layer and the second metallized layer are bondeddirectly together.
 9. The insulating packaging material of claim 2wherein the first polymer layer and the second polymer layer comprise atleast one of PP, PET, or HDPE.
 10. The insulating packaging material ofclaim 2 wherein the first metallized layer and the second metallizedlayer comprise aluminum foil.
 11. The insulating packaging material ofclaim 2 further comprising a valve configured to receive air to inflatethe first array of adjacent cells and the second array of adjacentcells.
 12. A method of forming a thermally insulating packagingmaterial, the method comprising: bonding a first multi-layer film to asecond multi-layer film at an interface, wherein the first multi-layerfilm includes a first polymer layer and a first metallized layer, andwherein the second multi-layer film includes a second polymer layer anda second metallized layer; inflating a first cell disposed within thefirst multi-layer film and the second multi-layer film, wherein thefirst cell comprises a set of orifices, each of the set of orificesbeing positioned on a different side of the first cell; inflating, byfluid communication with the first cell, a second cell disposed withinthe first multi-layer film and the second multi-layer film, wherein thesecond cell comprises one of the set of orifices of the first cell; andsealing a peripheral edge of the first multi-layer film and the secondmulti-layer film, wherein the peripheral edge is disposed along aperimeter of the first multi-layer film and the second multi-layer film.13. The method of claim 12 further comprising: inflating, by fluidcommunication with the second cell, a third cell disposed within thefirst multi-layer film and the second multi-layer film; and inflating,by fluid communication with the first cell, a fourth cell disposedwithin the first multi-layer film and the second multi-layer film. 14.The method of claim 12 further comprising: inflating, by fluidcommunication with the second cell, a third cell disposed within thefirst multi-layer film and the second multi-layer film; and inflating,by fluid communication with the third cell, a fourth cell disposedwithin the first multi-layer film and the second multi-layer film. 15.The method of claim 12 wherein sealing a peripheral edge comprises heatsealing the first multi-layer film to the second multi-layer film. 16.The method of claim 12 further comprising defining a bag comprising:sealing an additional edge of the first multi-layer film and the secondmulti-layer film, wherein the additional edge encompasses a lateralportion, the lateral portion arranged to form a bottom side of the bag.